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2 Interest ApproachNotice that these welds have been welded with fuel-gas, arc, MIG, and TIG welding.Can you tell what welding type was done on each? Compare and contrast each of them.What are the advantages and disadvantages of each process?

7 What are the advantages of using the Tungsten Inert Gas (TIG) welding process? What advancements have led to the development of the TIG welding process?

8 The Tungsten Inert Gas (TIG) welding process fuses metals by heating them between a non-consumable tungsten electrode and the base metal, while a continuous envelope of inert gas flows out around the tungsten electrode.

9 Tungsten Inert Gas WeldingThe letters “TIG” were used to designate the process.1. Later, the definition was changed to “gas tungsten arc welding” and the letters “GTAW” came into popular use.2. Today, both of the letters and names are used.

10 Advantages of TIGThe TIG process has several advantages that account for its popularity and increased use in the agricultural and welding industries.1. Welds made with a gas-shielded arc are more corrosion resistant, more ductile, and stronger because the gas is able to completely exclude atmospheric air from the welding zone.

11 Advantages of TIG2. Welds are not weakened by slag inclusion in the bead because the flux used is a gas.

12 The TIG ProcessThe TIG welding process is known for its consistency in producing high quality welds.The welding process is easier than other methods because the weldor can clearly see the welding zone.There is a minimal amount of smoke, fumes, and sparks created by the TIG process.

13 The TIG ProcessThe finished weld requires little, if any, grinding or preparation before it can be painted.There is usually less distortion of the workpiece because of the small heat affected zone.

14 The TIG ProcessThe TIG process has many applications because it can be used to make high quality welds in almost any metals and alloys.Welds can be made with the TIG process either by applying filler rod to the puddle or by fusing the base metal without a filler rod.

15 The TIG ProcessTIG can be performed by both automatic and manual techniques.TIG may be done in all positions.TIG may be used on a wide range of metal thickness.

16 What are the applications for the Tungsten Inert Gas (TIG) process?

17 With the technological developments made in TIG equipment, it is now the most versatile of all the fusion welding processes.

19 TIG ApplicationB. The TIG process can be adapted for welding in the horizontal, vertical, and overhead positions as well as the flat position.1. It is used extensively in applications where weld quality is critical, such as stainless steel piping systems.

20 TIG Application2. One limitation of the TIG welding process is the low deposition rate of the filler and metal.The TIG process will deposit less filler metal per pass than of the other processes.Because of the increased time needed to complete welds on thick metal, theTIG process is used most often on thinner metals.

22 In the TIG process, an arc is struck between the non-consumable tungsten electrode and the workpiece.

23 TIG ProcessThe thickness of the metal and the type of current being used determine the size of the tungsten electrode.The possible currents available are Direct Current Straight Polarity (DCSP), Alternating Current (AC), or Direct Current Reverse Polarity (DCRP).

24 TIG ProcessThe arc is covered by a layer of shielding gas which acts as the flux and keeps the nitrogen and oxygen in the air from coming in contact with the molten puddle.

25 TIG ProcessWhen the puddle is formed on the base metal, the torch is moved along the joint until the workpiece is fused together.1. A filler rod may or may not be used.

26 TIG ProcessIf a filler rod is used, it should be the same composition as the base metal.The filler rod is fed manually into the leading edge of the puddle.The torch may be moved in a semicircular motion to vary the width of the bead.

27 The movement of the TIG torch and applying filler rod is similar to the movement used in braze welding with an oxy-fuel gas torch.

28 What are the types of Tungsten Inert Gas (TIG) equipment and accessories and what is their function?

29 The equipment used for TIG is somewhat different from that used in stick welding and much different from that used in MIG welding.

30 TIG EquipmentA weldor should know that with certain accessories a regular AC, DC, or AC/DC welding machine can be fitted for TIG welding.

31 TIG EquipmentThe heat energy put into the metal being welded is dependent upon the amperage, arc voltage, and polarity of the arc.The term polarity is used in describing DC welding circuits and refers to the direction of current flow.

32 TIG EquipmentDirect current flowing from the electrode (–) to the workpiece (+) is direct current straight polarity, or DCSP.

33 TIG EquipmentCurrent which flows from the workpiece (–) to the electrode (+) is direct current reverse polarity, or DCRP.

34 TIG Equipment Most TIG welding is done with AC or DCSP current.When welding with AC, the machine will be either balanced or unbalanced.With AC machines, the current, in theory, flows in DCSP half of the time and DCRP half of the time.

35 TIG EquipmentWhen the current flows in the DCRP half of the cycle, the current is flowing from the workpiece to the electrode, causing a high resistance to current flow.

36 TIG Equipment This resistance makes the tungsten electrode heat up.The resistance occurs because the current is flowing from a large conductor, the base metal, to a concentrated point in the tungsten electrode.

37 TIG EquipmentWhen in the DCSP half of the cycle, the current is flowing from the electrode tip, a small conductor, to the workpiece, a large conductor.This direction of current flow has a cooling effect on the tungsten and enhances its current-carrying capacity.

38 TIG EquipmentWhen the AC machine does not compensate for the high resistance encountered in the DCRP part of the cycle, the sinewave is unbalanced.One-half of the time the voltage is higher than expected (DCSP), and one-half of the time the voltage is lower than expected (DCRP).

39 TIG EquipmentIf the AC machine does not have the circuitry to balance the sinewave, do not set the amperage for more than 50 percent of its rated capacity, or machine damage may result.

40 TIG EquipmentAC machines designed specifically for TIG welding will have a balanced sinewave.These welders have a special circuit that compensates for the DCRP part of the cycle, and the voltages in both halves of the sinewave are equal.

41 TIG EquipmentWhether AC or DC is used for TIG welding, a high frequency (HF) unit must be built into the machine, or a portable one must be attached to it.The high frequency unit produces high frequency voltage (several thousand volts) at a frequency of several million cycles per second.

42 TIG EquipmentThe current in the high frequency circuit is only a fraction of an ampere.Because of the high voltage and frequency, the current is carried on the surface of the conductor rather than penetrating throughout the conductor.

43 TIG EquipmentWhen TIG welding with DC current, the high frequency unit must be on in order to start the arc.Once the arc is stabilized, the high frequency unit is turned off.

44 TIG EquipmentOn DC machines using an add-on portable high frequency unit, the high frequency circuit will need to be turned off manually.On AC machines TIG welders with high frequency units are used to stabilize the arc and to ionize gases in the arc zone.

45 TIG EquipmentThe ionized gases make the arc easier to maintain when the current changes directions.

46 TIG EquipmentThe torches used on TIG welding outfits are electrical devices and have a duty-cycle rating.The duty-cycle is the maximum current that the torch can safely withstand over a 10 minute period of operation.

49 TIG EquipmentThe weldor should make sure all connections and fittings are tight.Small capacity TIG welding torches will usually be air-cooled rather than water-cooled.

50 TIG EquipmentThe purpose of the gas nozzles on TIG welding torches is to direct the flow of shielding gas over the welding zone and to decrease turbulence of the shielding gas stream.

51 TIG EquipmentThe volume of gas required and the width of the bead will determine the size of the nozzle needed.The shapes of some nozzles are designed to decrease turbulence of the gas stream.

52 TIG EquipmentWith some nozzles, the electrode may stick out as much as 1 inch without loss of the shielding gas and turbulence.

53 TIG EquipmentNozzles are made from ceramic, metal, plastic, and Pyrex glass materials.Ceramic nozzles are used on jobs up to 275 amps.Metal nozzles or metal-coated ceramic nozzles are used on jobs where 300 or more amps of current are needed.

54 TIG EquipmentHigh-temperature plastic and Pyrex glass are transparent and are used in some special applications.The electrodes used in TIG welding may be pure tungsten, tungsten with 1 or 2 percent thoria, tungsten with 0.15 to 0.40 per cent zirconia, or pure tungsten with a core of 1 to 2 per cent thoria.

55 TIG Equipment Pure tungsten electrodes are the least expensive.However, they have less current-carrying capacity and are easily contaminated.This makes them the least desirable for critical welds.To improve the electrical conductivity, add small amounts of thoria or zirconia.

56 TIG EquipmentElectrodes with 1 or 2 per cent thoria have good current-carrying capacity, maintain their shape longer, have good resistance to contamination, and make the arc easier to strike.

57 TIG EquipmentElectrodes with 1 per cent thoria are good for general purpose welds.Two percent thoriated electrodes are used for critical welds on aircraft, missiles, nuclear reactors, and heat exchangers.

58 TIG EquipmentThe quality of the tungsten-zirconia electrodes is between pure tungsten electrodes and the tungsten-thoria electrodes.

59 TIG EquipmentElectrodes may be purchased with a clean finish or a centerless ground finish.Clean-finished electrodes have a smooth surface, are free of defects, and are good for most GTAW jobs.Centerless ground electrodes have a mirror-like finish and are used on jobs where the highest-quality welds are needed.

60 TIG EquipmentWhen selecting an electrode, consider the following criteria: electrode diameter, amperage, type of current, type of shielding gas, and whether the high frequency wave is balanced or unbalanced.Electrodes must be shaped and sized before being used for TIG welding.

61 TIG EquipmentElectrodes which are contaminated or those which are too long to fit into the electrode cap must be shortened.The desired shape of an electrode after it is properly broken is a square, blunt edge.Electrodes may be broken with pliers, wire cutters, or a hammer.

62 TIG EquipmentThe electrode end must be correctly shaped after it has been broken.Some TIG welding jobs call for an electrode with a specific shape, which are used for critical welds.

63 TIG EquipmentFor most TIG welding jobs, a sharp, pointed electrode is used for welding with DCSP current, and a rounded, or balled, electrode end is used for welding with alternating current.

64 TIG EquipmentThe flowmeter is used to adjust the flow of shielding gas and is calibrated in cu. ft. per hour (cfh) or liters per minute (L/min.), or both.To get a correct reading of the volume of gas flow, the flowmeter must be installed so it is vertical.

66 TIG EquipmentWater-cooled TIG welding units have three hoses going to the torch.One hose will carry the shielding gas and is made of plastic to prevent chemical reactions that might cause contamination.

67 TIG EquipmentOne hose carries a combination of coolant and the electrode lead.The lead is a woven metal tube with good current-carrying capacity.The tube is covered by rubber or plastic-insulating material.

68 TIG EquipmentCurrent travels through the woven metal tube, and coolant passes through the middle of the tube.The third hose carries the return coolant to the storage reservoir or to a drain.

69 TIG EquipmentLight-duty torches are air-cooled and usually have only one hose connected to them, which is a combination electrode lead and shielding gas hose.The electrode lead may be either a woven tube or a flexible cable, and the shielding gas acts to cool the electrode lead as it flows to the torch.

71 What are the types of shielding gases used for Tungsten Inert Gas (TIG) and what are their purposes?

72 The purpose of a shielding gas in TIG welding is to protect the arc, electrode, and puddle from nitrogen, oxygen, and hydrogen in the air.

73 Shielding GasWhen the arc, electrode, or puddle comes into direct contact with the air, contamination in the form of oxides is formed on the electrode and in the weld.A brownish-yellow fume from the weld zone indicates that the shielding gas cover has been lost and that oxides are forming.

74 The shielding gases used for TIG welding are mostly argon, helium, and mixtures of argon and helium.

75 1. ArgonThe most commonly used gas because it is cheaper and 10 times heavier than helium.Argon is 1.4 times heavier than air and gives better control of the arc and weld puddle because it is a heavier gas than helium.

76 1. ArgonSince argon is heavy, lower flow rates are needed for welding in the flat position.The heavy shielding gas is a disadvantage for welding in the overhead position.

77 ArgonArgon has a lower arc voltage than helium does at any given amperage and arc length.The low arc voltage produces less heat and results in low base metal distortion and reduced chance of burn through, which allows it to be used for welding thin sections of metal.Argon has a quieter, smoother arc than that obtained with helium.

78 Helium shielding gas is used for welding thick sections of metal and when higher arc voltages and higher weld zone temperatures are needed.

80 Postweld purge timeThe length of time the shielding gas continues to flow over the weld puddle after the arc has been extinguished.This allows the puddle to solidify before it is exposed to the air.

81 The techniques used to perform TIG welds are quite similar to those used for braze welding with the oxy-fuel gas torch.

82 TIG Welding TechniquesFor TIG welding, the machine should be set on the smallest ampere setting that will get the job done.The welding speed should be as fast as possible.

83 TIG Welding TechniquesIn TIG welding, the puddle is small and results in a small heat-affected zone.Since there is no transfer of metal through the arc, there is no spatter.

84 TIG Welding TechniquesThe width of a TIG bead should be two to three times the diameter of the filler rod.

85 TIG Welding TechniquesThe TIG welding torch should be held at a 60 to 70 degree angle to the work.The filler rod should be at a 20 to 30 degree angle to the work.After the arc has been struck and the puddle has formed, add the filler rod to the leading edge of the puddle.

86 TIG Welding TechniquesWhen welding is stopped, the shielding gas should continue for a few seconds to prevent contaminating the molten puddle, tungsten electrode, and filler rod.A forehand welding technique is used for TIG welding.Most TIG welding is performed in the flat position.

87 TIG Welding TechniquesSet the shielding gas flow according to the recommended volume for the size metal and gas nozzle being used.Adjust the welding machine to the recommended amperage and type of current.Place the foot control in a convenient location and turn on the welder.

88 TIG Welding TechniquesDepress the foot control and strike the arc.When the puddle appears, add the filler rod to the leading edge.By moving the TIG welding torch to the rear of the puddle when the filler rod is added, you reduce the possibility of contaminating the tungsten.

89 TIG Welding TechniquesMetal cleaning and joint preparation are the same for TIG welding as for other types of welding.TIG welding is seldom used for metals over ¼ inch, except for aluminum and magnesium.When metals are less than 3 /16 inch, they may not require edge preparation.

90 TIG Welding TechniquesIf the metals are thicker than 3 /16 inch, the edges should be ground or machined so full bead penetration can be achieved.

91 TIG Welding TechniquesWhen welding a square butt joint, maintain the tungsten in the center line of the two pieces being joined.1. Use a 60 to 70 degree dray angle, a 90 degree work angle, and a 20 to 30 degree electrode angle.

92 TIG Welding Techniques2. Strike the arc and hold the tungsten approximately 1 /8 inch above the base metal.3. When the puddle forms, add filler rod to the leading edge of the puddle.4. Move the bead forward as rapidly as possible.

94 Tig Welding TechniquesWhen welding lap and T-joints in the flat position, tack weld the base metal pieces every 3 inches.1. The joints should then be set so the resulting welds are made in the flat position.2. Hold the torch at a 60 to 70 degree drag angle and a 10 to 20 degree work angle.

95 TIG Welding Techniques3. The work angle should point the electrode more toward the horizontal edge to be welded than the vertical edge.4. Strike the arc and allow the puddle to form.A “C”-shaped puddle should develop indicating that both edges of the metal are melting.

97 TIG Welding Techniques6. When the puddle forms, move the electrode toward the rear of the puddle and then add the filler rod to the front of the puddle.Then, move the electrode back to the middle of the puddle.Repeat this process as you move the bead forward.

98 TIG Welding Techniques7. When the end is reached, move the electrode toward the rear of the puddle to fill the crater with the filler rod and then withdraw it from the weld zone.8. Raise the TIG welding torch slowly to provide a gas shield while the puddle solidifies.

99 TIG Welding TechniquesFor welding in the horizontal position, the drag angle of the torch should be 60 to 75 degrees and the work angle should be a 15 to 30 degree angle.1. To keep the molten metal from sagging, maintain a smaller puddle than that used in the flat position.

100 TIG Welding Techniques2. Add filler rod at the upper edge of the puddle to help prevent sagging.3. Maintaining a 15 to 30 degree work angle will help the force of the arc to keep the puddle from drooping.

102 What are the safety practices that should be observed when TIG welding?

103 Observe the following general safety practices for working with TIG welding.

104 Safety ProceduresObtain the instructor’s permission before using any tool or machine.Wear a No. 11 or 12 shaded filter lens.The larger the tungsten electrode, the higher the lens shade number should be to prevent eye burn, strain, or fatigue.

105 Safety Procedures Good ventilation is essential for TIG welding.Ultraviolet rays may be 5 to 30 times more intense with TIG welding.These ultraviolet rays cause ozone to form.Ozone is harmful to breathe for extended time periods.

106 Safety ProceduresWear hearing protection when working with pulsed power and high current settings.Power pulses cause the arc to emit sound waves.Because the noise produced may be loud at high current pulses, hearing protection should be worn.Always wear gloves to insulate yourself from possible shock.

107 Safety ProceduresNever touch the tungsten electrode with the filler rod.The tungsten electrode is charged with electric current, which may charge the filler rod and shock the person welding.The current potential at the tungsten electrode is at the arc voltage level or higher.

108 Safety Procedures A shock from the filler electrode could be deadly.To protect yourself from such a shock, wear gloves and dry clothing and never touch the tungsten electrode with the filler rod.

109 Safety ProceduresNever touch your body with the tungsten electrode when the TIG welder is turned on.The high frequency unit built into the TIG welder is designed to stabilize the arc and to make arc starting easier.If touched while turned on, it will cause the unit to arc and can cause body burns.

110 Safety ProceduresThe danger of electrical shock is less with high frequency current than with current phasing at 60 cycles per second.The shock factor is reduced because high frequency current is conducted on the surface of the conductor rather than by penetrating into it.

111 Safety ProceduresThe surface conduction feature helps to minimize the danger for higher frequency current used in the TIG welding machine.Adjust the TIG high frequency unit only within the limits recommended by the manufacturer.This will help to reduce the possibility of shock and body burns.

112 Safety ProceduresMake sure the TIG welder is grounded as recommended by the manufacturer in order to prevent shock.